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Facial recognition/fingerprint to eliminate unauthorized operation?

Facial recognition/fingerprint to eliminate unauthorized operation?

  • 2025-12-16
This is a typical application scenario for special equipment safety management and digital transformation. The core objective is to achieve "person-certificate verification" through technological means, strictly eliminating the risks caused by unlicensed operation and mid-operation personnel changes.

In manufacturing plants, especially when operating high-risk special equipment such as forklifts and cranes, introducing facial recognition/fingerprint key technology is an efficient solution to meet the requirements of regulations such as the "Special Equipment Safety Technical Specification - Safety Technical Specification for Special Motor Vehicles in Plants (TSG 81-2022)" (e.g., requiring operators to hold certificates and preventing operation by non-operating personnel).

Intelligent Access Control and Unlicensed Driving Prevention Solution

I. Core Technology Application and Principles

Technical Means

Principle Description

Regulatory Compliance (TSG 81-2022)

Facial recognition

The device captures the operator's facial features through a camera and compares them in real time with the information of certified operators in the database. The device can only be started after the comparison is successful.

Article 4.1: Operators shall obtain a special equipment operator certificate.

Fingerprint key

Before starting the device, the operator must verify their identity via fingerprint, and the fingerprint information is linked to the operator's certificate number.

Article 4.2: The user unit shall establish a post responsibility system.

Electronic fleet management system (FMS)

It integrates positioning, sensor and identity recognition data to record vehicle status, operators, operation time and abnormal situations in real time.

Article 4.2: The user unit shall establish equipment safety technical files.

II. Application Scenarios and Implementation Process

1. Strict Authorization for Start-up – Preventing Unauthorized Operation

Data Binding: In the FMS system backend, each piece of equipment (e.g., forklift) is bound to a set of authorized (certified) operators' facial/fingerprint data.

Start-up Process: After boarding the vehicle, the operator must first undergo facial/fingerprint recognition.

The system compares the identity information in real time.

Successful Comparison: Vehicle start-up permission is released, the equipment is unlocked, and the operator's identity and start-up time are recorded.

Failed Comparison (Unlicensed/Unauthorized): The vehicle refuses to start and immediately sends an alarm message to the safety management personnel.

2. Mid-Shift Personnel Monitoring – Preventing Unauthorized Handover

Continuous Identity Verification: The system can be set to perform "on-duty verification" at regular intervals (e.g., every 30 minutes) during operation. If the operator is detected leaving their seat or the face in front of the camera changes, secondary identity verification is triggered.

Abnormal Engine Shutdown: If the equipment is operated or started by unauthorized personnel without following the system's "shift handover" process, the vehicle will automatically trigger a restrictive engine shutdown or low-speed lock.

3. Intervention for Fatigue Driving and Violations

Fatigue Detection: The facial recognition system simultaneously monitors facial expressions and eye status. If it detects fatigue characteristics such as excessive yawning or frequent eye closure, it will issue an alarm, forcing the operator to rest or requesting a replacement.

Speeding/Area Restriction: Combining identity recognition with onboard GPS/sensors, when an authorized operator is driving in an unauthorized area or exceeding the speed limit, the system will implement appropriate speed reduction or locking measures based on their identity level.


III. Compliance with TSG 81-2022 and Other Regulatory Requirements The application of facial recognition/fingerprint technology directly addresses core pain points in safety regulations:

Identity Traceability: Each operation has a precise timestamp, device number, and operator identity record, fully complying with the requirements for establishing safety technical files.

Mandatory Access Control: The system implements physical-level access control, bypassing subjective human judgment and transforming "unlicensed driving" from "possible" to "technically impossible."

Clear Safety Responsibility: Operational data clearly defines the responsible party for each operation, facilitating accident analysis and accountability.

IV. Implementation Challenges and Recommendations

Challenges

Countermeasures

Environmental interference

Choose industrial-grade, high-protection-level (IP65 or above) identification equipment to ensure accurate identification even in dusty, bright light, and vibration environments.

Wearing masks/helmets

It employs advanced liveness detection algorithms and multimodal recognition (such as face + fingerprint) to ensure accurate identification even when wearing a mask.

Data privacy

The collected and stored data must be encrypted and strictly comply with relevant national data security regulations, and shall be used only for security management purposes.

System compatibility

Ensure that the new identification system can interface with the existing FMS, ERP and other management systems in the factory via API to achieve data sharing and unified scheduling.

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